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Industrial Application of PLCs in Bangladesh

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International Journal of Scientific & Engineering Research, Volume 3, Issue 6, June-2012 1
ISSN 2229-5518

Industrial Application of PLCs in Bangladesh

Ahmed Ullah Abu Saeed, Md. Al-Mamun and A.H.M. Zadidul Karim

Abstract— A programmable logic controller (PLC) or programmable controller is a digital computer used
for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures.
The versatility and prospect of automation is so important that it could bring radical development in almost every aspect. In Bangladesh
different types of industries concerning manufacturing, printing, food, plastics, leisure etc are already using PLCs and others to go. But the
main problem lies in the dependency on the foreign consultants and engineers including reasonable amount of cost. In this cas e our effort
on PLC would be a solution. The immediate objective of the thesis is to study and test the applicability of PLC in aspect of Bangladesh. To
understand the necessity and application of PLC in industrial automation, a PLC based control system was applied in an automatic bottle
filling station using LOGO! 230 RC. In the bottle filling system the PLC gets the sensor feedback and controls the solenoid valve timing as
well as control the conveyer belt. It can fill two bottles with max height of 6.7’’ and max diameter of 4.7’’ in a minute. All the results lead to a
conclusion that the potential of PLC in perspective of Bangladesh is very inspiring.

Index Terms— Automatic Bottle Filling Station, Conveyer belt, Industrial Automation, Ladder Diagram, LOGO! 230 RC, PLC, Sensor.

——————————  ——————————

1 INTRODUCTION

A UTOMATION is the use of control systems and informa-

tion technologies to reduce the need for human work in
the production of goods and services. In the scope of in-
dustrialization, automation is a step beyond mechanization.
Whereas mechanization provided human operators with ma-
chinery to assist them with the muscular requirements of
work, automation greatly decreases the need for human sen-
sory and mental requirements as well. Automation plays an
increasingly important role in the world economy and in daily
experience [1]. PLC plays an important role in the world of
automation industry. It acts a major function in the automa-
tion field. PLC has replaced the wiring and cabling system
that were used in the previous. It’s soft wiring feature makes
changes in the control system easy and cheap. So in today’s
world it is very important to study PLC.
Most of the industries in Bangladesh now have started to
employ PLCs. PLC reduces complexity, increases safety, cheap
and PLC based automation system not only guarantees re-
duced production time but also a higher productivity both in
terms of quantity and quality. For these reasons everyone is
now willing to leave the conventional industrial control sys-
tem and switch to PLC. PLC is being used in many sectors in
Bangladesh. A few examples are - Manufacturing industries,
travel industries, printing industries, food industries, hospit-
als, plastics industries, leisure (Roller coaster ride and effects
control system) etc [2]. Also in some shops and restaurents
many PLC based devices are being used. Even PLC is used in
lift and escalator control systems. The application of PLC in
many sectors of our country is increasing day by day.
————————————————
Ahmed Ullah Abu Saeed is with the Department of Electrical and Electron-
ic Engineering, University of Asia Pacific (www.uap-bd.edu), Dhanmondi,
Dhaka-1209. Email: abusaeed_11@live.com.
Md. Al-Mamun is with the Department of Electrical and Electronic Engi-
neering, University of Asia Pacific (www.uap-bd.edu), Dhanmondi, Dha-
ka-1209. Email: almamuneee07@gmail.com
A.H.M. Zadidul Karim is with the Department of Electrical and Electronic
Engineering, University of Asia Pacific (www.uap-bd.edu), Dhanmondi,
Dhaka-1209. Email: zadid_aust@yahoo.com
IJSER © 2012
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The versatility and prospect of automation is so important that
it could bring radical development in almost every aspect.
And in case of automation PLC could be a vital tool. We have
specially chosen the PLC based system and the goal is to study
and test its applicability in aspect of Bangladesh. For this we
have directly applied a PLC based control system in an auto-
matic bottle filling station. In this paper we have addressed
the design and implementation of a PLC based automatic bot-
tle filling station. The whole paper is divided into several sec-
tions firstly this paper commences with a description of the
product. Then it gives the design requirements and how the
Programmable Logic Controller (PLC) was selected consider-
ing its features, others compromising factors and design re-
quirements. This paper then gives functional description of
the product. Finally, this paper describes advantages of the
proposed device, limitations, result, conclusion and discus-
sion.
2 ADVANTAGES OF PLC
1. High reliability
2. Small space requirements
3. Computing capabilities
4. Reduced costs
5. Ability to withstand harsh environments
6. Expandability
7. High power Handling
8. Reduce Human Efforts [3]
3 DESCRIPTION OF OUR PROPOSED DEVICE
It is a PLC based commercial kit. There are two parts of our
device namely
3.1 Hardware Part
Our proposed device is consisted of a PLC (LOGO! 230 RC)
[4], 24V DC Relay, 220V AC Relay, Sensor (PUYON KS-G22)
[5], Solenoid valve, Single-phase induction motor, conveyer
belt, 24 V DC Source, ON-OFF button and some connectors.
International Journal of Scientific & Engineering Research Volume 3, Issue 6, June-2012
ISSN 2229-5518
The ON-OFF button works as the input device. The PLC con-
trols the input and output according to the program provided
to it.
3.2 Software Part
There are five main programming languages for programma-
ble control systems: function block diagram (FBD), ladder dia-
gram (LD), structured text (ST; similar to the Pascal program-
ming language), instruction list (IL; similar to assembly lan-
guage) and sequential function chart (SFC). These techniques
emphasize logical organization of operations. [6]
In out proposed device Ladder Diagram (LD) is used. The
program is to interface the ON-OFF button and all the hard-
ware parts with the PLC.
4 FLOWCHART DIAGRAM
Flowchart diagram of the working process of the proposed
device:
Fig. 1. Flowchart diagram of the working process of PLC based au-
tomatic bottle filling station.
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2
When the start button is pushed the motor starts hence the
conveyer belt starts moving. When the bottle is under the so-
lenoid valve, the bottle is sensed and the motor hence the con-
veyer belt stops. Then the solenoid valve operates and the bot-
tle starts filling with water. When the bottle is filled then the
solenoid valve is closed and the motor hence the conveyer belt
start moving and carrying the bottle away from the solenoid
valve. If another bottle is sensed then the above process will be
repeated. When stop button is pushed then the entire process
will be stopped and reset the circuit.
5 SELECTION OF PLC
There are some main factors to choose a PLC for any applica-
tion. They are:
I/O
Size of Memory
Communications
Compatibility to HMI
Speed
Different PLCs have different number of I/O ports. And in
some, adding external I/O cards can increase number of I/O
ports. Memory Size is the memory amount available for the
code of PLC. In some PLCs, adding external flash cards can
increase memory size. Serial and networked connections allow
the PLC to be programmed and talk to other PLCs. The needs
are determined by the application. Human machine interface
and it is a very important feature of PLC. Using this one can
see the whole operation of the PLC program graphically.
Speed is also an important factor in choosing PLCs. But Now-
a-days PLCs are rapid enough for any kind of operation [7].
In the proposed device LOGO! 230 RC is used. In LOGO! 230
RC, there are 8 inputs and 4 relay type outputs. 4 ms full pro-
grams scan time and memory was more than enough for the
automatic bottle filling station. That is why it is chosen.
Fig. 2. LOGO! 230 RC.
International Journal of Scientific & Engineering Research Volume 3, Issue 6, June-2012
ISSN 2229-5518
6 PROTOTYPE DESIGN OF PLC BASED AUTOMATIC
BOTTLE FILLING STATION
Fig. 3. A PLC based automatic bottle filling station.
The PLC is powered by a 220V AC power supply through its
line (L) and Neutral (N) port. A Push button is connected from
the same source to the input card terminal I1. A sensor is po-
wered by a 24V DC power supply and its output is connected
to a 24V DC Relay coil. I2 input of the PLC is connected to the
NC terminal of the 24V DC relay. A 220V AC relay coil is con-
nected with the PLC relay type output port Q1 and from the
NC terminal of this relay the 1-phase motor of the conveyer
belt is connected. A solenoid valve is directly connected with
the PLC relay type output terminal Q2.
When the ON push button is pressed then the PLC input port
I1 gets a pulse and for this the PLC relay type output Q1 is
energized and the motor starts. Now when the sensor senses a
bottle then it gives a pulse to the DC relay hence the DC relay
operates. So the I2 input of the PLC gets a pulse and for this
the relay type output Q1 is de-energizes and Q2 energizes ac-
cording to the Ladder logic of the PLC. So the motor stops and
the solenoid valve operates for certain period of time assigned
in the Ladder logic of the PLC. After the assigned time PLC
relay type output Q1 again energizes and Q2 de-energizes. So
the motor again starts running and the solenoid valve be-
comes OFF.
Fig. 4. Practical view of our proposed device.
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3
7 SYSTEM SPECIFICATION
1. Input: 220 V AC
2. Capacity: 2 BPM
3. Maximum bottle height: 6.7’’
4. Maximum bottle diameter: 4.7’’
5. Maximum pressure: 1 bar
6. 1 filling Nozzle
7. Automatic shut off when bottle is full
8. Best liquide: Water
8 LIMITATION
It can only fill approximately two bottles per minute, which is
a little bit slow. The process can be efficiently used in water
filling system. The types of fluid to be handled is mainly dic-
tated by solenoid valve and nozzle used. So the range of fluid
types is not so wide. Positioning of the solenoid valve is a crit-
ical issue and proper care needed. Another disadvantage is
that there is no guide way for the bottles making the system
susceptible to imbalance vibration. This system is constrained
by height (max 6.7’’ inch) of the bottle of a specific volume.
9 RESULTS
The device can fill up 2 bottles of maximum height of 6.7’’ and
maximum bottle diameter of 4.7” in 1 minute at 1 bar pressure.
So it can be used commercially in various coffee shops, juice
shops, cold drink shops etc and reduce human effort. So the
practical research result is very much satisfactory. It also helps
to understand the necessity of PLC in industrial automation
and also to realize the necessity of studying it.
10 FUTURE WORK
Using appropriate pump, jet nozzle and strong solenoid valve
in which case precise timing would be needed can increase
productivity. A guide way could be used in case of vibration.
A non-intrusive water level sensor could be used instead of
depending on the valve timing. An extended capping section
could also be introduced. Another sensor could be used in the
beginning, which can sense the bottle and start the conveyer
belt automatically. More flexibility can be introduced in nozzle
positioning. The system could be redesigned for increased
bottle size and productivity.
11 CONCLUSION
Automation increases productivity, which in turn brings eco-
nomic progress. The role of PLC in automation is basically
controlling the whole system. The installation cost is not so
cheap but in the long run the reliability and performance of
the system makes up to the investment [1].
In Bangladesh different types of industries concerning manu-
facturing, printing, food, plastics, leisure etc are already using
PLCs and others to go. But the main problem lies in the de-
pendency on the foreign consultants and engineers including
reasonable amount of cost. In this case our effort on PLC
would be a solution.
International Journal of Scientific & Engineering Research Volume 3, Issue 6, June-2012 4
ISSN 2229-5518

The PLC based control system has been studied along with its Ahmed Ullah Abu Saeed has com-
prospects in this paper. A PLC based control system was ap- pleted B.Sc. Engg. (EEE) in the De-
plied to the automatic bottle filling station previously speci- partment of Electrical and Electronic
fied and the performance was measured. All the results lead to Engineering (EEE), University Of
a conclusion that the potential of PLC in perspective of Ban- Asia Pacific (UAP). Now he is work-
gladesh is very inspiring. ing as an Engineer in Baneco Solar
Energy Ltd
REFERENCES (www.banecosolarenergy.com).
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<http://en.wikipedia.org/wiki/Automation>
Md. Al-Mamun has completed B.Sc.
[2] "What Is a PLC. Who Uses Them and What For? What Does PLC
Engg. (EEE) in the Department of
Stand For?" Machine Information Systems Make a Very Good Machine
Electrical and Electronic Engineering
Shop Project. Find out Why? Web. 11 Nov. 2011.
(EEE), University Of Asia Pacific
<http://www.machine-information-systems.com/PLC.html>.
(UAP).
[3] "Advantages of Using Programmable Logical Controller [PLC] in the
Construction Industry." How PLC Can Optimize Performance in the
Construction Industry. Web. 05 Mar. 2012.
<http://www.chillibreeze.com/articles_various/advantages-of-
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using-programmable-logical-controller-810.asp>.
ing as an Assistant professor in the
[4] "SIEMENS - 6ED1 052-1FB00-0BA6 - LOGO! 230RC, 8DE/4DA, 200
Department of Electrical and Elec-
BLOECKE."6ED1 052-1FB00-0BA6. Web. 05 Mar. 2012.
tronic (EEE) Department, University
<http://uk.farnell.com/siemens/61-052-1fb00-0ba6/logo-230rc-8de-
of Asia Pacific (UAP). He joined at
4da-200-bloecke/dp/1657153>
UAP in April 2007 after completion
[5] "Supply Color KS-G22." Fiber Amplifier, Sensor, Proximity Switches,
of his BSc. Engg. (EEE). He has com-
Encoders, Counters, Relays, Thermostat .........-Guangzhou Heng Wei Elec-
pleted his MEngg. from BUET. Right now he teaches courses
tronics Co., Ltd.Web. 05 Mar. 2012.
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<http://waytop001.en.b2b168.com/shop/supply/5771301.html>
trical Machines, Electrical and Electronics Circuits. Besides
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this, he is a convenerof EEE Sports Club.
Web. 22 Oct. 2011.
<http://en.wikipedia.org/wiki/Programmable_logic_controller>.
[7] "PLC, PLC LADDER, PLC SIMULATION, PLC PROGRAMMING,
FREE PLC TRAINING." The Factors to Consider When Selecting PLC.
Web. 05 Mar. 2012. <http://program-
plc.blogspot.com/2011/11/factors-to-consider-when-selecting-
plc.html>.

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